Lens Mirror Array Positioning With Resin Holder Draft Taper
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of accurately positioning a lens mirror array on an optical path using a resin holder is exacerbated by the need for a draft taper, which complicates the manufacturing process and can lead to issues with surface accuracy and alignment, particularly when the holder is made of resin.
Innovation Solution
The lens mirror array is designed with first and second positioning surfaces that are orthogonal to the optical axis, allowing for separate placement on the holder, enabling the use of resin holders without requiring the first and second contact surfaces to be on the same plane, thus facilitating the provision of a draft taper for easy release from the die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin holder is used instead of a metal holder, then manufacturing cost and ease of manufacture are improved, but the ability to provide a flat contact surface for accurate positioning deteriorates due to the need for draft taper
Solution Approach 1:
The patent introduces a third dimension by tilting the contact surface relative to the optical axis. Instead of requiring both contact surfaces to be on the same plane (2D constraint), the first contact surface is tilted at a specific angle, allowing the holder to be released from the die in the draft direction while maintaining positioning accuracy through the tilted geometry. This dimensional change resolves the conflict between draft requirement and flat contact surface requirement.
Solution Approach 2:
The patent employs asymmetric positioning where the first contact surface is tilted at a specific angle relative to the optical axis, while the second contact surface remains perpendicular to the optical axis. This asymmetric configuration allows the resin holder to provide both the necessary draft taper for easy release and a sufficiently flat contact area for accurate positioning, overcoming the limitation of symmetric flat surfaces.
2Ease of operation
If a draft taper is provided in the resin holder, then ease of release from die is improved, but the flatness and accuracy of the contact surface for positioning deteriorates
Solution Approach 1:
The patent segments the contact surface into two distinct surfaces: the first contact surface with the tilt angle for draft and release, and the second contact surface perpendicular to the optical axis for positioning. This segmentation allows each surface to fulfill its specific function independently - the first surface enables easy release while the second surface ensures positioning accuracy, resolving the contradiction between ease of operation and manufacturing precision.
3Manufacturing precision
If the first and second contact surfaces are on the same plane, then positioning accuracy is improved, but the ability to provide draft taper for resin holder release deteriorates
Solution Approach 1:
The patent moves the first contact surface from the same plane as the second contact surface to a tilted plane at a specific angle. This dimensional change in orientation allows the draft taper to be provided in a different direction, enabling resin holder release while maintaining the positioning accuracy function of the second contact surface on its original plane.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design allows for improved manufacturing precision and reduced changes in illuminance, enabling a compact configuration and enhanced alignment of the lens mirror array, even when using resin holders, thereby maintaining optical performance and reducing manufacturing complexity.
Implementation Method 1
an incident-side lens surface that refracts and converges incident light
Implementation Method 2
a first reflection surface that reflects incident light made incident via the incident-side lens surface in a direction toward an optical axis of the emission-side lens surface
Implementation Method 3
a second reflection surface that reflects light made incident via the first reflection surface in a direction toward an optical axis
Data Source
AI summary
An optical element of a lens mirror array according to an embodiment includes an incident-side lens surface, a first reflection surface, a second reflection surface, an emission-side lens surface, a first positioning surface, and a second positioning surface. The incident-side lens surface refracts and converges incident light. The first reflection surface reflects light made incident via the incident-side lens surface. The second reflection surface reflects the light reflected by the first reflection surface. The emission-side lens surface emits the light reflected by the second reflection surface. The lens mirror array is a lens mirror array in which a plurality of optical elements are arrayed in a direction orthogonal to optical axes of the incident light and the reflected light and parallel to the first positioning surface.